Dutton Kit Cars and their owners

Welded diff awaiting new diff carrier and planet gear

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Albums: Jan 2011

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Comment by Dave Price on January 19, 2011 at 20:54

Following the advice and comments received from people here and friends (and friends parents) I have decided the full diff rebuild would be hard work.  So I have had a fresh look at the diff.  I had planned to rebuild it to remove the welded carrier and replace noisy bearings.  The bearings sounded gritty, but there is no play, so I rinsed the diff out with white spirit.  Bearings now run smooth, so only need to change the diff carrier.  Therefore if I am leaving the pinion in place the reuild work may be easier.

Comment by Adrian Southgate on January 18, 2011 at 18:22
We have a diff / axle specialist about a mile away from us in westhoghton, I will be taking mine there to be dismantled and after painting and cleaning all the bits it will be going back to be reassembled by them.Cuts down on the labour costs and I get to supply all the parts at cost.
Comment by Adrian Southgate on January 18, 2011 at 18:17
I've got a couple with fittings on but if doing a rebuild why not go for a sierra handbrake cable as it is adjustable at both ends not just one side with a balance rod. It will mean welding a small tube or bracket on the casing on the right side of the car to match the one on the left. Makes the handbrake a bit more effective too.
Comment by Dave Price on January 18, 2011 at 11:58
I didn't think you were dismissing my capability.  I understood you were simply warning me of the pit falls, and I apreciate the advice.  You are now part of a growing band of people warning me against doing this (you are the second).  Now I am being to think, I am doing the right thing?  But I am still tempted to have a go
Comment by Dave Adams on January 18, 2011 at 10:06
I was not trying to sugest that you weren't capable of rebuilding a diff, just warning you to be fully aware of what you attempt. As a mechanic, I have often had to fix problems caused by a little knowledge and too much enthusiasm. Any competent mechanic can do it so long as he is methodical, but it is very easy to get it wrong with a diff.
Comment by Dave Price on January 17, 2011 at 21:39
Thanks for the comments.  I have also read things (like haynes manuals etc) that say the diff  rebuild is a specialist job.  I have also read things that just say you have to be competent.  So based on the theory that I would put myself in the competent group (rebuilt a number motorbike engines, car engines, gearboxes, agricultural equipment etc) I thought I would have a go.  The biggest issue I can see is setting the correct backlash.  I have some reference documents that explain how to do this by coating the gears with engineer's blue and studying the marks left on the teeth as you rotate the pinion, or use a dial gauge.  I will give it a go and if I fail at least I have tried and then I will have to go and buy another diff (so thanks for the contact for a diff).  I will let you know how I get on.
Comment by Dave Taylor on January 15, 2011 at 11:14
David, if you've not bought the parts yet, you may want to give these guys a call GS Escorts in Widnes, Cheshire 01514228333. As the name say's they specialise in old and new Ford's 3:9 / 3:89 diff is about £55.00. they do mail order. They advertise in Classic Ford every month. It secondhand but if you were to get a bad one they will swap it.
Comment by Dave Adams on January 15, 2011 at 8:19
You ever rebuilt a diff? i have a 3.54 diff with dead pinion bearing and whilst the bearings are not expensive to buy, (C-70 quid) removing and refitting the new ones looks a pain without a decent press, also setting the pinion to crown wheel position, and getting the backlash right is a bit specialised. i have several books with the methodology in them but i still don't fancy the task. And i have rebuilt all sorts of things on various engines and cars over the years that i was told were not possible to strip and rebuild. Get a diff wrong and it will last a few weeks at best.
Comment by Dave Price on January 14, 2011 at 20:47
Spent two evening this week cleaning this diff ready for rebuilding.  I did not think it would take so long to remove the years of grime and oil.  Well it's now ready to be dismantled and rebuilt with new bearings
Comment by Adrian Southgate on January 11, 2011 at 21:39

No problem.

Just give me a shout if you get stuck for parts and I will make an axle available to strip.

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